Blast furnace start-up delayed

Earlier this week, Essar Steel Algoma reported it would begin the start-up process on its damaged #7 blast furnace today.

Published reports notwithstanding, it didn't happen.

"We have completed a comprehensive physical inspection of the bustle pipe main and our inspection has led to additional repairs which we have deemed necessary," Brenda Stenta, Essar Algoma's manager of corporate communications, tells SooToday.com "As a result, the start-up timeline has been altered."

Now, the start-up is expected to begin late Friday or early Saturday.

Stenta says the process will be slow and controlled, taking three to five days in total before #7 is producing hot metal.

As reported earlier by SooToday.com, the blast furnace has been on a gradual cooldown for the past 14 days since a catastrophic failure of its bustle pipe main forced the company to suspend production of hot metal.

"A failure in the pipe's metal shell resulted in a hole approximately 14 feet across," said Stenta today.

"By way of context, the bustle pipe main is comprised of a metal structural shell and a refractory lining that protects the metal from the heat of the hot air blast," she said. "We have completed a very thorough inspection of the entire system, both the refractory and the exterior shell, and have changed any areas of potential concern."

Essar doesn't anticipate any undue noise or abnormal emissions from start up.

#7 blast furnace was producing an average of 8,000 tons of hot metal per day before it was idled due to the failure of its bustle pipe main at about 2:30 a.m. September 24.

The bustle pipe main, which carries hot air blast to the furnace, failed in the area above the north tap hole.

No one was injured in the resulting ejection of hot blast through the hole in the bustle pipe.

Essar Steel Algoma emergency service and operating personnel responded immediately, isolated the area and began inspections.

Production at the cokemaking and cogeneration facilities has not been affected by the incident at #7 blast furnace, Stenta said.

The plate and strip hot mill was taken down for maintenance this week, she said, having pulled ahead some previously scheduled work.

"Operations continue at all finishing mills," Stenta said. "The Plate and Strip mill will resume production on Monday using the existing slab inventory."

No temporary layoffs have been announced.

"All primary areas remain engaged in the repairs," she said. "Operating personnel in those downstream areas affected by the shutdown have been permitted to take vacation or if possible, have been redeployed."

Essar Steel Algoma has not yet been able to estimate the cost of the damage to #7 blast furnace and subsequent production time losses.

It has also been preparing #6 blast furnace, a hot steel-making furnace of considerably less capacity than #7, to be restarted as a back-up if needed.

Stenta said this process will take about two weeks.

***************************